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Old 03-07-2017, 08:45 AM   #1
vincent9993
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Default Project: Meyers Manx Manxter 2+2 SS with FA20T

I thought I'd share the project I'm working on. We're building a street legal Meyers Manx Manxter 2+2 S.S. Dune Buggy and we're using a donor WRX 2015 for the motor. It is mated to 2004 Impreza 5SP transmission with a reverse-cut ring & pinion from Subarugears.

Although Subaru EJ, Corvair, Ford Ecotech and even a few Porsche 914 motors have been used in these builds, we're only the 2nd to attempt using an FA20T in this buggy.

There are a few interference issues but we're working through them.

We started with a running 1971 Super Beetle and converted the front end to a Ball Joint for a Std Beetle. These buggies don't need to be shortened but we replaced the pans and sandblasted the whole frame. It was then painted with POR15.

We then sourced a wrecked WRX 2015 from Copart with 14,000 miles and imported it to Canada (for parts). We made sure the engine ran before we pulled it and we photo documented the whole disassembly. (Having access to the manuals really help). This car came with a CVT and it can't be reversed (and is too big to fit in the buggy) so we sourced a 2004 TY754 5SP from a friend. The input shaft bearing had seized so I replaced all the bearings, forks and synchros before installing the reverse-cut ring & pinion.

As I said earlier, there are some interference and challenges to deal with in this project. I got close by lifting the body 1" but the TGV and EGT were still hitting the back of the body so they had to go.

Next was cooling, since the motor is in the back and we opted to run 2 side pod radiators. The initial quote for custom race radiators came in at close to $1K/ea. I'm going to try to run RZR radiators. The ports are a little smaller but I'm hoping it won't be too much an issue. I'll report back later. Routing the radiator hoses will require some clever thinking. I'm hoping I can flip the pump output to point to the back of motor to help with routing the hose. The return on top of motor will need a 180 hose.

The intake will probably come straight up on the side of the valve cover. I'm not planning on running a shield but the whole area is exposed so getting clean/cold air should not be an issue. K&N makes a pretty simple intake that I'm hoping I can run right off the turbo inlet.

I'll be running the intercooled in the rear wing and the charge Pipe will need to come straight up. Looking at the different products, it looks like PRL's 2 piece may be the best option. I would only run the bottom piece and add a hose to connect it to the intercooloer. The output into the intake will need a 180 or 135 hose to clear the back of the buggy.

The exhaust also needs to make a 180 turn to exit the back. I've purchased the Killer-B 3" J-Pipe and plan to fab an exhaust out of 3" stainless exhaust tubing to mate up to a Greddy muffler. It may be a little loud, we'll see.

The last piece is going to be wiring... I've been studying the wiring diagrams for the past few months and getting familiar with where everything needs to go. The immobilizer is going to be challenging but I'm hopeful.

Here are some pictures of the project.

Donor Super Beetle


Beetle head end conversion


Beetle frame


Beetle pan


Donor WRX




Engine pull




The engine


Some wiring required...
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Old 03-07-2017, 08:47 AM   #2
vincent9993
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Power train mounted to VW pan


The Manxter




Radiators


Exhaust
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Old 03-07-2017, 08:51 AM   #3
vincent9993
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Here's a picture of the other Manxter in Australia running an FA20T

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Old 03-07-2017, 08:53 AM   #4
CGumina
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This is going to be so bad ass.

Can't wait to see how this thing responds to having 275lbs/ft+ under boost!
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Old 03-07-2017, 10:39 AM   #5
Charlie-III
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Silver Sleeper BK, 5MT

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Looks like a fun project.

The only VW Beetle based kit car I worked on was a 1930's vintage Alfa Romeo open wheel race car on a narrowed Beetle pan. That was senior year high school.
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Old 03-07-2017, 11:15 AM   #6
Steemax
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LBP

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Wow .... this gon' be good.
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Old 03-10-2017, 07:01 PM   #7
Zefy
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99 2.5TS (DEAD)

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cool project!
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Old 03-14-2017, 04:50 PM   #8
whiplash willy
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ISM

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Looks like a cool project! Just out of curiosity, how much did the 2015 WRX end up going for at Copart?
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Old 03-14-2017, 05:13 PM   #9
vincent9993
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Quote:
Originally Posted by whiplash willy View Post
Looks like a cool project! Just out of curiosity, how much did the 2015 WRX end up going for at Copart?
My winning bid was $4K + around $500 in fees.
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Old 09-06-2017, 08:20 PM   #10
essjayarr
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Hey Vincent99993,

Do you simply hang the Subaru engine off the transmission same as an aircooled bug motor?
I've studied pictures of the Mendeola builds using even the larger 3.0 6 cylinder Subaru motors, and I can not spot any engine mounting towards the front of the motors.
I've done several Subaru powered Vanagons using the 2.2, but the kits for these use their own engine crossmember or the Vanagon stock crossmember.
Also I have done a 2.2 Suby into a '73 Superbeetle using a Kennedy adapter and hung it off the adapter with no other support. As far as i know, the new owner to this day has had no issues.
I did talk to Kennedy and their position is "We don't recommend hanging the engine off the adapter plate. It is possible the upper studs could be pulled from the threaded holes.
What do you think?
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Old 09-06-2017, 09:44 PM   #11
Homemade WRX
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This is going to surprise some poor fools. I like it!
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Old 12-21-2017, 10:29 PM   #12
brad131a4
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Any thoughts on running the complete drive train? Would like to know if it would be feasable with the stock front end from the bug.
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Old 12-28-2017, 08:33 PM   #13
olivergoss
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Cant Wait to see it finished!!!
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Old 01-15-2018, 03:17 PM   #14
rexxx0486
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Awesome project! Any updates?
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Old 02-18-2018, 09:13 PM   #15
W.E.Scoob
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WRB

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Another waiting for updates...
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Old 02-19-2018, 11:47 PM   #16
KHWRX
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Nice build. Would definitely like to see some videos!
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Old 02-25-2018, 06:57 PM   #17
vincent9993
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Got the motor started with my custom wire harness. She sounds mean without the cat... I'll post a video soon...
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Old 03-01-2018, 07:23 AM   #18
vincent9993
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We have a tradition in our club to eat our cake in the buggy for our birthday. This year I made this short video starting the Manxter and eating my cake.

You'll get a small glimpse of the progress so far.

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Old 03-14-2018, 04:45 PM   #19
KyleCosgray
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That thing is dope! big VW guy at heart. Love it
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Old 11-07-2018, 07:23 PM   #20
Not_FLman
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Liberals are trolls
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Old 11-07-2018, 07:30 PM   #21
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Liberals are trolls
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Old 11-19-2018, 10:28 AM   #22
vincent9993
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Just checking in, making good progress on the project. We've got the DBW pedal adapted to the stock ECU. Got the buggy to move under its own power...

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Old 11-19-2018, 01:14 PM   #23
subaru_gc8
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Quote:
Originally Posted by vincent9993 View Post
Just checking in, making good progress on the project. We've got the DBW pedal adapted to the stock ECU. Got the buggy to move under its own power...

https://youtu.be/U-37l3kmM-s
Nice!!
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Old 11-28-2018, 02:28 PM   #24
fartbox420
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does it have a limited slip dif?
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Old 11-29-2018, 08:10 PM   #25
ggogle
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When is your projected end date? How much do you work on it? I might be attempting a FA swap on a bugeye and wonder how long it would take me.
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